PROJECT PROFILE FIBRE FOAM FOR SEAT CUSHION AND BEDDINGS

Transcription

1 PROJECT PROFILE ON FIBRE FOAM FOR SEAT CUSHION AND BEDDINGS July 2013 PREPARED BY K S TECHNICAL AND MANAGEMENT CONSULTANTS, VADODARA, PH: FOR OFFICE OF TEXTILE COMMISSIONER, MINISTRY OF TEXTILES

2 INDEX CHAPTER PAGE PRODUCT AND ITS APPLICATIONS 2 AN OVERVIEW OF MARKET 3 SUGGESTED PROJECT SIZE 4 RAW MATERIALS: AVAILABILITY, REQUIREMENT AND COST 5 TECHNOLOGY ASPECT 6 MANPOWERAND UTILITY: REQUIREMENT 7 INFRASTRUCTURE RQUIREMENT 8 PROJECT COST AND MEANS OF FINANCE 9 FINANCIAL PROJECTIONS 10 CRITICAL FACTORS / KEY ELEMENTS 11 RAW MATEIAL, PLANT AND MACHINERY SUPPLIERS 12 1

3 CHAPTER I Product and its Applications Fiber foams are a substitute for the conventional PU foams. These are produced using Hollow cross section Polyester fibers bound together with low melt fibers or bonding chemicals. The Performance of Fiber based foam is acceptable for many end uses. The technology of making foams using fibers has been perfected in the last few years and many high end applications have already started using these fiber foams in place of conventional Polyurethane foams). Fiber Foams are produced using a Pollution free Thermo bonding Process. The Fiber foams have distinct advantage of a Non-Toxic process unlike conventional foams which use high poisonous chemicals like MDI or TDI (Toulene Di Isocyante). Formation of foam like structure using Polyester fibers is achieved through melting the surface of a small percentage of fibers or with adhesive spray and bonding them simultaneously. Fiber foams can be made Flame Retardant by using the right type of Polyester Fiber. The bonding is done by binder fibers or adhesives, the quantity and type of fiber can engineer the properties required in the end use. Fiber foams can be produced from as low as 30 gms per sq m and upto 3000 gms per sq m. Generally for most applications, a low melt Polyester fiber or Polypropylene fibers are used in the range of 5 to 10% depending on the properties desired in the final products. The typical end uses for fiber foams can be categorized into two types: 1. Technical Uses a) Sound Absorption device in Auditoriums b) Noise Attenuator in Automotives c) Sound Insulation in Domestic Appliances d) Air filter in Desert coolers and Air Conditioners 2. Commodity Uses a) Foam Substitute in furniture and Bedding b) Covering of PU foam for better comort c) Filling inside Quilting d) Thermal insulation pads for light weight washable carry bags e) Water resistant purse linings etc., f) Washable wadding in winter wear g) Distribution layer in Hygiene( Diaper and Sanitary napkins) An important criteria is that these are recyclable whereas the competing chemical foam product is non-recyclable. 2

4 CHAPTER II An Overview of the Market The Global market for Nonwovens is estimated to be about 7 million tons and nearly 12% of this market (840,000 tons) is estimated to be manufactured using thermobond technology. The applications of fiber foam for technical uses is at infancy in India, as most of the existing manufacturers are having equipment that is suitable for making only low density and light weight products. It is the capability to produce high density and high weight product that will increase the user base for this product. Currently the production in India for wadding is estimated to be around 35,000 tons per year. This is produced mainly on second hand and localized equipments and are capable of producing nonwovens upto 600 gms per sq m. They are generally used in Quilting used on the surface of Foam beddings. Due to export of Garments from India and overall increase in manufacture of ready made garments the market projected is nearly 80,000 tons in the coming years. The market size will increase when better uniformity products and high density foam is produced. The technical end uses of this market in acoustics, thermal insulation and seating foams is itself expected to generate a demand of tons in the coming years for these applications only. The fabric is generally produced in a minimum width of 1.5 mtr. Currently there are about 25 wadding manufacturers in India spread all over the country who are producing low density material in the weight range 50 to 500 gsm. These are made on second hand conventional machines which are capable of producing low density product only and are sophisticated enough to make High density foams upto 3000 gms per sq m that is envisaged in this project for Upholstery, Bedding, Automotive, Thermal insulation, Noise control end uses. The significant players in the market in India are 1. Gokuldas Exports, Bangalore- Makes wadding for Garments and quilts 2. Suvi Exports- Delhi Makes Waddings for Quilts 3. JP nonwovens- Mumbai- Makes waddings for quilts and Garment industry 4. Jhanji Textiles (P) Ltd., Delhi- Makes a wide range for quilts and insulation 5. Venus Interlinings Private Limited, Jaipur- Makes wide range for quilts 6. Star Comfort Industries, Bengaluru 7. Khushee International, Rajkot- Polyester and Cotton based waddings 8. Times Fiberfill, Kolkata- Waddings for Quilts and Beddings industry 9. Klin Products, Morbi- Wadding for Mattress and insulation 3

5 CHAPTER III Suggested Project Size and Location Currently the products are produced in India on low capacity lines. These have technical limitations in terms of density of product, uniformity and range of product to be produced in one line. A 3 mtr wide line with capability to produce products in the weight range 60 to 3000 gms per sq m is proposed in this project report. The estimated capacity for this project is about 1500 tons per annum maximum, depending on the product being produced. The machinery has to be imported from China, Korea or Europe and configured to make a wide range of products for the Indian market. 4

6 CHAPTER IV Raw Materials 1. 3D x 44 mm length- Polyester Hollow fiber 2. 6D x 51 mm length- Polyester Hollow Fiber 3. 9D x 60 mm length- Polyester Hollow Fiber 4. 6D x 44 mm length- Low melt Polyester fiber 5. 6D x 44 mm length- Teijin Elastomeric fiber 6. 6D x 44 mm length- PP fiber 5

7 CHAPTER V Technology Aspect The choice of Nonwovens machinery and Raw materials used are important for the achieving the final product performance. The Manufacturing Process of Fibre Foam has following steps Fiber Opening Fiber Blending Carding Laying Thermo bonding in Ovens Winding or Sheet cutting The bonding of fibers is done by the low melt fibers. To get a good quality material it is essential that these 5 to 10% bonding fibers be blended homogeneously with the Polyester hollow fibers. To achieve this effectively, mixing bins are used in blending. A thorough blending also gives a uniform product. Carding using air lay cards are found to be more effective particularly for the higher weight products. High capacity thermo bonding ovens with proper heat transfer design is essential for achieve a product uniformity and good output. Using Direct Gas burning is the most cost effective way of providing energy for the production line. When high quality thermo bonding is not demanded by the end use, it is quite common to use Poly Propylene fiber as binding fibers. To get a highly resilient foam, special fibers are available from companies like Teijin. These improve the elastic recovery of foam produced and also give more comfortable feel to the product. 6

8 CHAPTER VI Manpower and Utility for 3 shift working Manpower Plant Manager 1 Shift Supervisors 4 Operators 35 ( including helpers 15 nos.) Technicians 4 Marketing Manager 1 Accts/Admin 3 Sales 5 CEO 1 Total 54 Utilities Installed Power Opening and carding Thermal Bonding oven drives Gas or fuel for oven burner Thermo bonding oven Compressed air 150Kw 30Kw 8 cu mtr/hr or 80KW heating 5NM3 /min 7

9 CHAPTER VII Infrastructure Requirements Land Plant Building Requirements Utilities, compressor and other area Raw Material storage and Finished goods storage- Office Building Effluent: 1200 SQ M 40 mtr length x 10 mtr width x 5 mtr height 10 m x 5 mtr 10 m x 10 m 10 m x 7 m NIL 8

10 CHAPTER VIII Project Cost and Means of Finance PARTICULARS Rs. Lakhs Land 1200 sq m x 900 per sq m 11 Building 620 sq m x 6750/sq m 42 Plant and Machinery- imported Korea $ Million x Rs.60/$ Lighting, air conditioning etc 25 Margin for Working Capital 125 Total 1343 Means of Finance PARTICULARS Rs. Lakhs Capital 403 Term Loan 940 Total

11 CHAPTER IX FINANCIAL PROJECTIONS PARTICULARS FIRST YEAR PRODUCTION AT 60% CAP Utilisation 792 TPA ( 100% capacity 4000 Kg /day)-330 days PRODUCT- Average 300 gms per sq m SALES PRICE PER Kg Rs. 170 RAW MATERIAL Polyester fiber 75/kg+ low Rs. 95 melt 200/kg -5% CONVERSION COST Rs. 35 per Kg OPERATING MARGIN PER Kg Rs. 40 per Kg OPERATING PROFIT per annum Rs. 316 lakhs Payback Period Estimated 3 years 10

12 CHAPTER X Critical Factors / Key Elements 1. Availability of thermal energy at competitive rates is essential for the project to be competitive. 2. Skilled operators are required for reducing operating wastages 3. Consumers for the product within short distance from the factory. This will reduce transportation cost for the bulky material like fibre foam. 4. Closeness to industry segment for which major production is sold. Typically like Filtration, Auto seats or furniture or bedding or noise control etc. 11

13 CHAPTER XI Machine Suppliers S. No. Name of Supplier Country of Origin 1. Trutzschler Germany 2. Santex Switzerland 3. Jiangsu Jingcheng China 4. Shyngwei China 5. Boo Kwang Tech Korea 6. Yin Yang China 7. CTMC China CHAPTER XII Raw Material Suppliers Polyester Fiber S. No. Name of Supplier Country of Origin 1. Reliance Industries Ltd Mumbai 2. Indo Rama Industries New Delhi 3. Futura Organics Chennai 4. Teijin Fibers Japan 5. Advansa Turkey 6. Chang Lang China 7. Dafa chemicals China Polypropylene Fiber Zenith Fibers Radici Asota Domo fibers Baroda Italy Austria Belgium 12